Surface covering material



Feb. 11, 1941. N. P. HARSHBERGER I sunmcs comune MATERIAL Filed' ocx.11; 1937 4 sheets-sheet 1 R O T N E V m l MlgdnfMfx/rqgaf ATTORN EY Feb.11, 1941. N. P. H-ARSHBERGER SURFACE COVERING' MATERIAL 4 Sheets-Sheet 2Filed oct. 11, i937 INVENTOR I /l/vrffmn Hari/lnger ATTORNEY Feb. 11,v1941.

` N. P. HARsHBERGl-:R 2,231,006 sunmcsicovnnrne MATERIAL 4 lSheets-'Sheet 3 Filed oat. 11` 19:57

ATTORNEY Patented Feb. 11, 1941 T FFMC gf SURFACE COVERING TEApplication October 11, 1937, Serial No. 168,389

19 Claims.y

This invention relates to building materials, particularly shingles,strips, slabs, clapboards, insulating panels and the like, and tocoverings thereof, both singularly and in combination, for

5 walls, roofs, and other exposed building surfaces. Particularly, theinvention relates to composite units and surface coverings thereofcomprising a substantially stiff base, preferably of considerablethickness and possessed of good l insulating properties, and an outercover member of flexible composition roofing such as is generally usedand well known to those skilled in the art. The invention furtherrelates to a preformed covering element of flexible compol sitionroofing for composite constructions and for vsurface `coverings of thelap type, wherein butt edges of substantial thickness are exposed toproduce ornamental and deep shadow effects, and which element has beentreated as by a 20 hydraulic cement composition. Moreover, the inventionalso relates to processes of fabricating the novel products of theinvention and to methods of constructing surface coverings employingsuch products.

25 It is the principal object of my invention to overcome many drawbacksto the greater useof fiush wallboard and lap siding employing, in wholeor part, the usual composition roofing material which generallycomprises a felted brous 30 base treated with asphalt or other waterresistant material, as by saturating or impregnating the lbasetherewith, and coated uponthe exposed surface and edges, and sometimesupon the rear surface, with an adhesive coating of asphalt or 35 otherwater resistant materials. Such base material also generally has a layerof granular particles, for example, mineral particles of slate, tile,sand or the like, secured in the adhesive upon at least the exposed sidefor ornamenta- 40 tion and to provide protection for the bitumenadhesive.

It is Well known that the asphalt coating ingredientsv of this materialare subject to condensation or polymerization in exposure. 'Ihis resultsin drying out, checking, ,and crumbling of the coating. It materiallyaffects the bond of the surfacing granules and the material as a Wholeis subject to curling, and where bonded as a facing to other material,to delamination. 50 The material is further susceptible to physical-damage in handling,vapplication, and in treading upon, becauseof itsflabby character and softness of its constituents under warm climaticconditions, and must therefore be carefully 55 handled.

Moreover, when combining this common material with a core or lath toobtain heavy butt effects, one method isfor the applicator-to fold orotherwise form the roofing sheet about the core or lath, after securingthe latter to the 5 support. It will be understood that this procedure,particularly in cool weather, induces fracture and breaking of thematerial at the bends. To avoid this difficulty, thecovering may be madea permanent part of the core by an adl0 hesive bond, as asphalt, but thematerial is then subjected to delamination and curling, warping andbulging in exposure. Moreover, the applicator must then stock completedunits in many colors, which is a costly procedure. Preferably, the corepiece is preformed and detachable but I have found that the usualcomposition roolng, because of its flexible body and thermoplasticingredients, will not retain shaping and that folded and otherwisepreformed portions lose their shaping before use. It would be a nuisanceto the applicator to reshape the pieces in assembly, not considering thetime and labor involved. Thus, it will be evident that in addition tothe natural disadvantages of the usual composition roofing, additionalproblems confront those who would use this material for its desirableproperties in the making of wallboard and thick butt lap eifects and,therefore, limit its use for these purposes.

Accordingly, it is the general object of the present invention to obtaina more satisfactory commercial product useful as a separate element of acomposite product or as a permanent part thereof, by treating thecomposition roofing member to -be exposed with a rigidifying coating toimpart considerable `stiffness to the material at all workingtemperatures, enabling its easy handling in substantial sizes and toprovide shape retainment for any formedy portion, to resist sub- 40stantial deformation instorage and use, and to provide weather and reprotection for. the bitumen and the structure of whichtheproduct isapart.

Another general object of my invention vis the provision of materialsand the formation of surface coverings simulating structuralconfigura-f' tions, thick butt shingle effects, lap siding.;f and thelikel and preferably' simultaneously providing improved insulation.

A furtherA object is the provision of a weather exposable productcomprising a substantially stiff or rigid sheet-like layer of insulationmaterial and a layer of covering material upon the portion to beexposed, improving the insulating properties of the base layer andproviding weather and fire protection for the composite unit. f Anadditional object of my invention is to provide a covering member usefulas a shingle or `cover piece for an additional base or core, whichcomprises a flexible base an/d a rigidifying coating of suflicientthickness, for instance, a phenolic resin, but preferably a hydrauliccement composition, applied thereto 'to impart stiffness to the basewhen hardened, to enable its satisfactory handling, particularly whereof considerable size, and which base may include formed marginalportions made substantially shape-retaining by a similar coating.

Still another object of my invention is the provision of a compositeunit comprising a base and a detachable cover piece having a. formedmarginal portion with bends of shape-retaining character andinterlocking or intertting with the base, and which base and cover pieceare adapted to be laid asia single'unit in the formation of a. surfacecovering and when so laid possess individual freedom of expansion andcontraction.

Another object is the provision of a bitumen treated brous wallboardlayer and an ornamental facing comprising a hydraulic cementcomposition, whereby greater rigidity is obtained and warping inexposure is avoided, and whereby large sections may be readily handledand fastened to a supporting structure by a minimum of fasteners.

Still other objects and advantages of my invention with particularrelation to the combination of materials and structure and the novelformation of surface coverings will more readily appear or be suggestedto those skilled in the art by the following detailed description andfrom the accompanying drawings forming a part thereof, wherein certainembodiments of my invention are presented for a better understandingthereof although it will be understood that I do not desire to belimited to the specific embodiments hereinafter disclosed.

Referring to the drawings wherein similar parts are denoted by similaridentifying numerals:

Figure 1 is a` perspective view partly in section of the principalcomponents of a composite unit made in accordance with my invention.

Figure 2 is a cross sectional view of a modied butt portion constructionof a composite unit made in accordance with my invention.

Figure 3 is a face view showing a section of a siding or other `surfacecovered with composite units of my invention.

Figure 4 is a cross sectional view taken at 4 4 of Figure 3.

Figure 5 is a partial cross section taken through the joinder of a pairof courses 0f composite units showing a modied construction inaccordance with my invention.

Figure 6 is a further modication of my invention showing the use of aprojecting nailing means.

Figure '7 isa cross section of a modication of the structure in Figure6.

Figure 8Iis an assembly of a modified construction in accordance with myinvention.

Figure 9 is across sectional vview taken at 9-9 of Figure 8.

Figure 10 is a cross section of another modication 0f my invention.

Figure 11 is a face view of an assembly of a further modification.

Figure 12 is a cross sectional view taken at |2-I2 of Figure 11.

Figure 13 is a face view of a further modified covering construction ofmy invention.

Figure 14 is a cross sectional view taken at |4-I4 of Figure 13.

Figure 15 is a face view of an assembly showing the elements of myinvention as used with a clapboard siding.

Figure 16 is a cross sectional view taken at I 6--I6 of Figure 15.

Figures 1 and 2 generally disclose forms of composite units embodyingcertain basic features of my invention. These units comprise a base orelement IU of stili or rigid characteristics, to be covered, andpreferably comprising a body of compressed or cemented vegetable and/ ormineral fibrous material, for instance, bagasse, wood, sub.

stantially pure cellulose, paper, asbestos, mineral wool, animal hair,and others, usually used either alone or in combination, or adapted tobe used in the making of products generally known to those skilled inthe art as wallboard or insulating board. One formI of commercial boardof this character which I may use is marketed under the name' Celotex.The fibrous base may be of the same structure throughout or may, for theadvantages obtained in certain constructions hereinafter to bedescribed, comprise a plurality of separate sheet-like plies I2 bondedface to face by suitable cements to form an integral structure.

The fibrous material comprising the base may be rendered waterproofand/or fire-resistant by treatment with suitable agents such assilicates or bitumens, for instance, asphalt, tar or pitch, butpreferably with a synthetic resin composition, for instance, comprisinga phenol aldehyde resin or other known synthetic materials adapted toproduce Water insoluble and impervious lms after evaporation of suitablesolvents combined therewith. Such treatment may extend into one or morefaces and edges of the base or throughout the base structure as bycoating, saturating, or impregnating. Where the base is a laminated one,one or more plies only, preferably the outer ply may be treated,particularly where porosity, with its advantages of heat and soundinsulation and lightness of mass, are desirable characteristics. Thetreatment may also be confined'to certain sections of the base,particularly where said sections are to back up weather joints offurther covering material. Furthermore, the base may be renderedWater-resistant by incorporating a water emulsion of bitumen orsynthetic resin with the fibrous material prior to forming the samevinto sheet form.

The base may be made into various forms and thicknesses but for thepurpose of this invention it is preferred that the average thickness ofthe base be in the order of 1/4 to 1". It willof course, be understoodthat lesser or greater thicknesses may be employed. The base may also beof the well known composition roofing previously described, and may be aplurality of layers of such material bonded together to form a layer ofsubstantial thickness. Moreover, it may be found desirable to employ abase of a hydraulic cement ber composition made into sheet form by lowor high pressure. The material known as Transito is an example of asheet made by high pressure, but such will be considerably heavier thanthe bases of equal section made by a low pressure process. Bases ofother cementitious and fiber compositions are also contemplated, as wellas bases of any of the aforesaidtypes where the ingredients comprising1'the -same have been processed or treated with foams orgasifyingsubstances to render themmore porous and lighter in weight, andto improve theirinsulating characteristics. Further, bases of bitumenmastic em- A ploying scrap materials as fillers are also contemplated.It will also be understood that the base Il) may be further treated withany of the `materials previously described to convey to the same anadditional protective coating or surfacing.

The base covering, preferably a detached and loose member, is generallyreferred to by the numeral I4, and preferably comprises a waterresistantfoundation layer and a surface layer comprising a rigidifyingcomposition. In Figure 1,

- the covering I4 is shown to comprise a foundation layer of compositionroofing, comprising a flexible felted fibrous layer I6 comprising any ofthe fibrous materials -heretofore mentioned, preferably impregnated orsaturated with a low melting point asphalt and coated with a furtherbituminous or resinous layer I8,'also of any of the.

types heretofore mentioned. In the coating layer I8 is partiallyembedded and bonded a layer of individual granules 20, such as of slate,brick, tile or cement. Such composition roofing may be made in themanner disclosed in my prior Patent No. 1,913,667granted June 13, 1933.

The covering I4 has a. body portion 22 and Aretroverted or underturnededge iiange preferably extending the length of the butt edge. As shownin Figure 1, this ange comprises a substantially straight lip portion 24connected by a bend rto the body portion and a narrow lip 26 generallyparalleling the body portion connected by a bend to the portion 24. Itwill be seen that the portion 24 covers the butt edge faceof the base Ito extend weather protection to the whole butt end of the base.Likewise, it will be noted that the base is slightly chamfered at theedge corners to compensate for any slight bulge of the covering materialat the bends. ltwill also be observed that the shaped portion is made tosubstantially freely fit the base III, i. e. the distance between theinner faces of the lip 26 and body portion 22 being substantially equalto thebase IIJ thickness at the position covered. Thus, the p0rtions 24and 26 create hook-like extensions to be interlocked or substantiallyfit the base and be come anchored thereto without external fastening.

It has been found that because of the pliable and thermoplasticproperties of the ordinary bitumen composition material aforesaid, it isdiilcult for this material, especially in warm weather, to retain instorage or otherwise the character of shaping here described. The lip 26would readily distort, particularly where several inches or more inlength. Likewise, the portion-2`426 would readily sag toward or awayfrom the body 22, opening or closing the distance which it is desirableto substantially maintain in order to obtain proper fitting in assembly.rIn either case, if the covering were used during cool wea/ther or whenthe bitumen was chilled, cracking at the bends might occur when forcingthe hook into proper position. Moreover, some movement could also occurafter assembly during warm weather, where the lip 26 was not nailed orotherwise fastened to fthe support, and to a lamer extent where theportion 22-24 was bonded in a well known manner to the base I0.

Accordingly, it is another feature of my invention to provide a formedcover element of the character described with means to resist de-'formation and toobtain other desirable properties. To accomplish thisend, I provide the outer side of the bends comprisingthe formed portionwith a rigidifying layer 28. In the structure of Figure l, bends occurat the junctions between portions 22 and 24, and 24 and 26 respectively.The coating preferably comprises an argillaceous material, preferably ahydraulic cement, of which Portland and oxychloride cements areexamples, but I prefer a high early strength cement because of irtsadvantages during processing of developing the strength of the shapedportion as rapidly as possible. An example of such a cement is thatcommercially obtainable under the name Incor. Preferably still, I employa high aluminate cement possessive of high early strength and propertiesof the character more fully described in my copending application SerialNo. 738,875, led August 7, 1934, for the many additional characteristicsI obtain therefrom. It will be noted that the coating or layer 28 in thestructure of Figure 1 is applied over the granular surfacing 26 andcovers the exposed adhesive between the granules. I have found that acoating in the order of 20 lbs. per 100 square feet will provideconsiderable rigidity at the bend, generally sufIicient to prevent anynormal sagging or spreading of the open formed portion. By increasingthe coating thickness, say to 40 lbs. or greater, the rigidity willmeasurably increase.

It will be understood that the coating or layer 28 may be of, any colorand mayinclude any of the extending materials and be applied in themanner more particularly referred to in said copending applicationSerial No. 738,875, or in any `other suitable way. As previously stated,when the coating is applied over the bends and becomes hardened,rigidity is imparted to the treated portion and any tendency of theportions forming the bends to normally or otherwise spread, ismaterially resisted. It will be appreciated that the cement layer 28provides a section highly resistant to compression, in which conditionit is substantially placed by reasonbf its position in the structure,when spreading tends to occur. Preferably, the layer 28 extendscontinuously over and between the bends of a formation such as shown inFigure 1, thus avoiding any bending or deformation between the bendsthere disclosed. Moreover, the layer entends preferably over the wholeof the lip 26 to rigidify and stiften the edge portion to avoiddistortion and especially to provide a suitable leading edge that Willnot turn when engaging a base Il) in assembly. Furthermore, the layer 28is made to additionally cover the body portion 22, at least the portionto be exposed, thereby imparting rigidity to the body portion 22 andmaking it easy to handle in assembly. It will be recognized that suchrigidity is of considerable value when the element to be j handled is ofconsiderable size and the coating layer 28, it will be understood,overcomes the natural ilabbiness of the base material.

. Thus fthe cement layer 2'8 provides an advantageous function withrespect to each'` portion of the cover piece covered by it and incombination with the base I6 provides a lightweight cover: piece capableof providing weather and fire resistance and capable of use as adetachable or permanently secured member with the base I0. Furthermore,in the stated structure the layer 28 shields in the bituminous coatingsof the element and resists the deteriorating action heretoforeencountered with the base material cornprising the covering.

It will, of course, be understood that the described features areobtained with formed portions, other than that shown in Figure 1. Forexample, the shaped portion may comprise a single bend as in the coverpiece 30 of Figure 2, where the base 3-2 is fully rounded. Furthermore,the shapedportion may readily be al base as 22, having a single bentportion in the nature of the portion 24. It will also be understood thatsag of the projecting portion is principally dependent upon theresistance of the bendy at the junction with the main body portion, andin certain instances it may sumce to extend the layer 28, as shown inFigure 2, only over the outer bend 34. In such a construction theportion 36 will obviously retain its full pliable characteristics andwill have the advantage of being adapted to be fitted to varying basethicknesses. The lip 36 may be made a minimum in thickness where spacesufficient to accommodate a cement-treated leading edge is not provided.Also, the portion 36 may provide a two sided bituminous seal, such beingsecured where the portio-n 36 is faced with a skin coat of thermoplasticadhesive and the rear face ofthe covering I4 is similarly treated. Theseskin coats will adhere to the contacting surface under the action ofabsorbed heat in exposure. A,

Additional rigidity, particularly with light weight layers, may beobtained by creating upon the treated side of the base before or aftershaping the portions 24 or 26, a plurality of ribs 38 separated bynarrow and deep valleys 40. The ribs preferably will extend around thebend or bends, that is, at an angle to the line of bend, and such angleneed not be a right angle. The ribs may be narrow and the valleys 4Dpreferably are narrow and may even be less than le" in width, and willpreferably be as deep as possible. -In addition to providing rigidity,the riblike surface will provide a pleasant architectural effect sinceit will be possible to simulate woodgrain effects and the like. However,it will be understood that the base and/or coatingmay be embossed orotherwise coated to produce ornamental visual eiects in the way ofdesigns or Structural configurations. Moreover, the coating or layer 28may have colored granules pressed therein to provide an artisticsurfacing and to serve as a means of separation in curing.

Where the coating 28 extends over the leading edge of the shaped portionas, for example, at 42 on the cover piece of Figure l, the edge ispreferably made with a chamfer or tapered portion. This may beaccomplished in any suitable manner, for example, by pressing the edgeportion prior to the application of the layer 28.

It is also within the purview of my invention to make light weightncover pieces wherein the foundation layer I6 is one of a cement-fibercomposition molded with shaped portions of the character of that ofFigure l, which are inherently stiff and do not require a furthercoating or layer of hydraulic cement to obtain rigidity.

Moreover, while I have disclosed the advantages of a hydraulic cementfor the purposes of my invention, I have found that the desirablecharacteristics are obtainable, at least to some extent, by the use ofcertain synthetic resins of the type heretofore mentioned, which, whenhardened, form a stiff film or layer. I, therefore, contemplate the useof such materials in certain cases as the coating 24. Also, suchmaterials or even starches are contemplated as temporary stiffeningagents during the shaping process prior to the application of thehydraulic cecent facing 24. In such instances, it is preferred that thestiffening agent be applied to the rear face of the covering I4.

Where the cover piece I4 is to be provided with a cementitious or otherrigidifying coating, such may De applied to the base material before orafter a web of the same is formed into sections l0 of suitable size. It,Will, of course, be understood that where bends or folds are formedupon the cover piece, such operations should be carried out prior tocoating or before the coating material has hardenedjin order that therigidifying funcl5 tion of the same shall be obtained in the formedstructures.

In one mode of making the cover piece I4, it is preferred to provideindividual sections of the cover piece material and to pass the samethrough a steam chamber, causing the material to be made limp and.formable without cracking the component parts thereof, and tosubsequently pass the same to a folding machine from which the materialemerges with folds, for example, as that disclosed in Figures 1 and 2.Thereafter the formed pieces are treated with the rigidifying coatingmaterial to render the formed portions resistant to deformation. It is,however,

also contemplated to bring the steam treated limp 30 covering materialI4 and sections of the base Il) together at the folding machine and toperform the folding operations employing the base I0 as a form.Thereafter, if the cover material has not previously been treated withthe rigidfying coating, the cover pieces may be thus treated while stillin combination with the base I0 or separately, if such base sectionshave been separated from the formed assembly. It will be furtherunderstood that while it is preferred that the cover pieces and basesections be maintained as separable units in View of their manyadvantages in assembly, the pieces may be integrally connected as bysuitable stapling in portions not to be exposed in assembly or by anadhesive coating placed between the under face of the cover piece andthe contacting face of the base I0. Adhesive may, if desired, be thebase saturant or coating material and may be a biturnen such as asphaltor pitch, a synthetic resin adhesive such as a phenolic resin, and maybe, in certain instances, a silicatey binder, for example, sodiumsilicate or even a hydraulic cement, where the nature of the adjacentsurfaces will permit proper anchorage thereof.

While the rigidifying coating, particularly a cementitious coating, maybe applied in various ways known to the art, it is preferred that theprocedure described in my copending application Serial No. 26,770, filedJune l5, 1935, and that in the application of Thomas Brady, Serial No.114,909, filed December 9, 1936, be followed. As described in theseapplications, the material to be coated is passed below impellingelements which carry a charge of the coating material 6 and which impelsaid material against the material to be surfaced therewith. It will beevident that by proper arranging it is possible to use the indicatedapparatus not only to coat sheets having their surface to be coatedfacing upwardly ly to provide shape-retaining properties for the bend inthe portion coated, in which case the coated portion will appearsomewhat as shown in Figure 2.

Where the rigidifying coating is a hydraulic cement, the coated materialwill be cured in a manner more particularly described in my Patent No.2,044,786, that is, the coated sections will be preferably stacked andcured in such operation. It has been found preferable to maintain thematerial in a curing room maintaining a temperature in the neighborhoodof 95 F. and 95% relative humidity, in `orderto prevent loss of moisturefrom the coated edge portions of the pieces and to avoid dustingefilorescence. In certain instances, particularly where a bend of anysize has been formed, it is contemplated to cure the cement coated covermember while combined with its base 2. AIn this manner, shaping of thecover piece is maintained during lthe critical curing stage andadditional handling operations may bemade unnecessary where thecomposite structure is desired for a surface covering. Where this typeof curing operation isperformed, it is preferred that the base 2 be onetreated with a water-repellent material of any of the types heretoforementioned to prevent inltration of moisture and also, where necessary,to provide a desirable separating means between the compacted layersduring curing.

The foregoing comprises the preferred basic combining elements of myinvention. It will be appreciated that the individual elements may bemodied at will, with particular regard to their shaping and design andthe combining features be used in various ways.A `In the gures of thedrawings to be described below, certain arrangements of the basicelements are set forth by way of example, each presenting certainfeatures of construction desirable for specific applications. While Iwill not mention the same, it

will be understood that the cover pieces and bases employed in theseconstructions may includ any one or all of the features, with particularreference to construction and materials employed, of the preferred basicbases and cover pieces hereinabove described. It will likewise beunderstood that I do not limit myself to the same, as materials otherthan those specifically recited may be used where the characteristics ofmy invention are obtainable therefrom. Furthermore, it will beunderstood that' certain features hereinafter to be described, may beem'- ployed without special regard to the materials of constructionused, and While certain types of foundations are indicated in thevarious figures, the elements of the invention may be used overstuddings, laths, boarding, clapboard sidings and old roong, these beingmerely by way of example. Also the featured cover pieces may be usedseparately, as with previously applied shingle elements.

Referring to Figures 3 and 4, the latter figure discloses a partialcross section of a siding covering-applied to a supporting boarding orsheeting vsurface 5U, and: whichvcomprises courses of base elementsf,preferably of insulating board, laid as indicated lingligure 3, with thelongitudinal ends thereofsubstantially in abutment and havngcover pieces54 assembled therewith. The base 52 is preferably of tapered crosssection and generally of greater length than depth, the constructionbeing such that units of considerable length may be made by reason ofthe stiiness provided. Moreover, the base has its greatest for improvedinsulation.

thickness at the butt end and the butt edge face is recessed to receivethe upper edge portion of a composite unit of a course below. Thisrecess forms two lips or projections 56 and 58 respectively, the lip 56projecting edgewise at the outer 5 surface and 58 edgewise at the rearsurface. It will be particularly noted that the rear lip is of greaterdepth than the face lip. This feature enables attachment ofthe base tothe support with concealed nailing as the lip is of suilicient depth 10to receive nails or other securing means and is readily reachable inassembly without interference by or injury to the outer face or lip 56of the base. I

It will be seen that the cover piece has a hook 15 portion 60 at thebutt edge, which ts over the lip 56 and has an upper edge portion -62folded over and about the upper or thin edge portion of the base. Inthis manner the cover piece is readily held to the base without othermeans of 20 attachment and where lthe cover piece includes acementitious or other rigidifying coating, it will be understood thatthe cover piece may be slid endwise over the base. Such may be done atany time during or prior to application to the 25 support. However, thecharacter of the structure here disclosed permitsA permanent attachmentof the cover piece to the base prior to assembly. This may beaccomplished, for instance, by a suitable adhesive between the rear faceof 30 the cover piece and the front face of the base. It will be notedthat the recess between the lips 56 and 58 is somewhat tapered inwardlyand thereby readily receives the upper edge portion of a unit comprisingtwo thicknesses of cover material and the base portion. It will beunderstood that where the cover piece is a permanent part of the base,the folded over portion S2 may be omitted, as it will be seen that theupper edge portion of the outer face of the cover piece 40 will be heldby the outermost face of the recess.

The elements are assembled commencing with the uppermost course ofunits, 4a row of nails being secured through the upper edge portion ofthe rst course of units and a ller piece 64 be- 45 ing providedotocreate in the first course, as well as in the subsequent courses, deadair spaces 66 Obviously, these exposed nails will be protected by theeaves of the structure. In addition thereto, nails 68 will be 50 securedthrough the projecting lips 58 of each unit. Subsequently, the nextcourse of units will be positioned, the upper edge portion of each unitbeing fitted into the recess in the lower edge of the adjacent courseland nails will be secured through the lips 58 of these elements asbefore. Obviously, .in this course and ,succeedingl courses, no upperedge nailing y will be required. It will also be notedthat by thislmanner of assembly, the tapered effect of the units permit a slightwedg'ing in theI recesses ofvother units to obtain tight joints, andthat the upper edge portion of each unit conceals the nailing of theprevious course of units. Also, a pleasing clapboard effect 1 isobtainable.

With further reference to Figure 3, it will be noted that the bases andcover pieces may be the full length of the course or may have any lengthdesired. Thus, the'length of the composite elements may bey 1' or 4.depending upon 70 the size of unit it is found most desirable to handle.Where joints are createdas at 1B, some provision mustfbe made to preventseepage of water to the supportand to the base material. particularlywhere it has not been treated to make it weather-resistant. Toaccomplish this, joint or batten pieces 12, generally pieces of fabric,such as felt, treated with a water-resistant compound, such as asphaltor synthetic resin, are provided to be used in conjunction with thecover pieces to form end laps of weathertight characteristics. It ispreferred for reasons of handling and fitting, that these pieces berelatively stiff. To provide for the joint piece 12, theouter face ofthe base 52 is preferably recessed to receive this layer. This is donein order to avoid producing any bulge of the cover pieces at the jointbetween adjacent sections thereof. The pieces 12 will be of sufiicientthickness to provide long life and will have suicient width to preventleakage of water due to side drive of rain at the joints. pieces are apermanent part of the base, the ends of the bases should be recessed sothat about half of the joint piece 12 laps each end of the adjacentbases at a joint. However, where the cover pieces are disconnected withrespect to the base, it will be seen that it makes little differencewhere the joint piece is positioned, that is, the base may be recessedat a point spaced from its end providing that the cover pieces fit overthe joint between adjacent base sections. joint or batteri piece 'I2 ispreferably a loose piece, but it will be understood' that the same maybe cemented to the base or cover piece where desired.

In Figure 5, I have shown an arrangement of composite units havingparticular suitability for attachment to flush boarding or studs. In thedrawings a studding construction is shown, the units being mountedagainst spaced horizontal boards 14, which are first secured to theuprights or studs 16. The composite units each comprise a base 18 oftapered section and a cover piece 80, the lower edge of which isretroverted to form a hook. It will be noted that the butt edge portionof the base 18 is recessed to form, as in the bases of Figure 4, a pairo f projections or lips 82 and 84 respectively, the rear lip 84 beinglower than the front one 82, so that it may be, as previouslyexplained,used as a nailing means. The recess, in this instance, is narrower thanthat of the bases in Figure 4, as it need only receive the twothicknesses of cover piece material. Thus, it will be appreciated thatthe bases in this construction may be much thinner in section than thoseof Figure 4. A further feature of the arrangement consists in theabutment of the adjacent horizontal edges of bases of adjacent courses.Thus, the lower edge face of the lip 84 acts as a registration for thenext lower base 18. In this manner the position of the horizontal jointsmay be predetermined and the boards 14 may be positioned and nailed tothe studs 16 so as to back up the horizontal joints between courses ofunits and provide a backing against which to nail the lips 84. The faceof the cover piece 80 is of greater depth than the base 18, and whenassembled it projects above the upper edge thereof and may be slid intothe edge recess of the bases of the next higher course. Thus, thehorizontal joints between the bases of said adjacent courses will beprotected from the weather. It is further preferred that the projectingportion betreated in the manner heretofore described for the hookportion to give it sufficient rigidity to enable ready assembly into therecess of the adjacent base.

Unless the cover pieces are cemented in position as they `are mounted,it is further preferred Where the cover Thethat they be factoryfabricated as a part of the base to prevent their displacement. Thevertical joints between cover pieces may be protected by joint or battenpieces 86, indicated by the dotted line in Figure 5, in the mannerdescribed with respect to the units of Figures 3 and 4. The courses ofbases will also be assembled, working downwardly from the top of thesurface to be covered, and it will be noted that the lip nailing is theonly fastening that is required, the rigidity of the cover piece facingfollowing treatment being suicient, together with this nailing, toprevent displacement of the bases.

In Figure 6, a construction of composite units is provided comprisingbases 88 and cover pieces 90, wherein the lower end of the base requiresno recessing. As with the cover pieces of Figure 5, each such element isprovided with a hooklike lower edge portion and the upper portion of thecover piece extends beyond the upper edge of the base 88. In thisconstruction, the hook portion of the cover piece is of sufficientsize-to receive the whole butt edge portion of the base. Unless thecover pieces be cemented to the bases during application, it ispreferred that they be a permanent part of the base and made so duringfactory fabrication as by a suitable cement. The composite units aresecured to a wall or the like by formed pieces 92 attached to a buttedge portion ,if the base pieces. These may be the entire length of thebase pieces or may be narrow sections of finger-like construction spacedapart over the length of the base. Obviously, in the latter instance,the number used will be determined by the length of the unit. However,at least two should be provided. It will be observed that the strip 92is formed as to have substantially three sections, one secured to thebase, a second at an angle to the rst and .projecting away from the rearface of the base, and a third in a plane substantially paralleling therst and projecting below the butt edge of the base so as to provide anexposed and accessible nailing tab, through which to secure a nail orother fastener to mount the units in position. The pieces 92 may be madeof metal, for instance, sheetmetal, or may be of any compositionmaterial, for instance, a strong fabric strip treated as by a saturantor coating, for instance, a synthetic resin, to render themshape-retaining. The strip 92 may be wholly rigid, but preferably hassome flexibility.

The purpose of the middle section `of this strip 92 is to space the baseaway from the mounting surface a suicient -amount to permit theprojecting portion of the cover piece of a next lower course to beinserted behind the butt of the overlying units, and simultaneouslycover and protect the said nailing strip and its fasteners. Where thenailing strip is of suiiicient thickness, it may be made of such depthin vvthe projecting portion as to provide by its lowermost edge,'a pointof registration for positioning the nextlower course of bases, that is,it may act as a stop' for the upper edge of the bases of the next lowercourse. The nailing strip 92 may be secured to the base by rivets orother fastening means 94, which extend Ithrough or only partially intothe base 88.

It will be understood that the nailing strip fea-- ture here describedmay be employed with other siding units where no cover piece isemployed, for example, where the siding unit is a sheet of fiber cementor the like. In such instances, it will be preferred that the fasteningmeans for the nailing strip be embedded in the composition material andconcealed therein, or that if the nailing strip be a narrow member `thefirst section thereof be embedded in said material before it has set orhardened. The units here described will be assembled in courses startingfrom the top and Working downwardly, unless the cover .pieces be securedat the time of application, in which case the bases may be mountedcommencing from the top or bottom of the surface. It will also be notedthat in the con-struction of Figure 6, dead air spaces are provided atthe back of each unit.

In Figure 7, a construction of composite units similar to that of Figure6 is shown, with the distinction lthat the elements are assembled so asto lie close to the wall surface to which they are secured. The ba-sepiece there shown, denoted by the numenal 96, has its butt edge portionnotched out to receive the retroverted portion of the cover piece 98there shown. Moreover, the notching is of suiiicient depth as to alsoreceive the upper edge portion of the cover piece of the next lowerc-ourse of units. In addition, the nailing strip |00 is a flat memberand will, therefore, be more readily packaged for shipment.

It will be understood that in the constructions of Figures 6 and 7, thatbatten or joint strips |02, as indicated by the dotted lines in saidfigures, may be provided -to protect the joints between cover .pieces inthe same course. These strips should project above the upper edge of thebase` pieces as far as the cover strips.

In Figures 8, 9 and 10, forms of sliding construction are illustrated,wherein the cover pieces of the composite units are intended to beseparable from the insulating base pieces and separately mounted. Thearrangements are particularly adapted for ush mounting and to producethe eect of a cl-apboard siding.

In Figure 9, the butt edge of the base piece 04 is formed with a notchproducing a lip |06, which overlaps the composite units of a coursebelow. The cover piece |08, which is treated to provide the novelfeatures described with respect to the basic cover piece .|4 of Figure1, has a hooked edge portion to fit the lip |06, and is substantiallythe depth of the base |04. In applying the units; the base pieces of acourse are secured to the supporting surface by fasteners such as nailsH0 secured through the butt portion of the bases |04. Next, the coverpieces |08 are hooked over the lip portions of the base pieces andpushed upwardly as far as they will go, the lower edge of the lip |06acting as a stop. Nails or other fasteners H2 are then secured throughthe cover piece and base .piece ladjacent the upper edge of thecomposite structure in a position Where they will be covered by Atheprojecting 4lip of the next overlying course of units. When one courseof units have been laid, the next overlying course of bases are-positioned with the lip portions |06 thereof overlying the coverfastening means of the next lower course and with the upper end of thenotch at the butt of the base pieces abutting the upper edge of the basepieces of the said subjacent course, thus producing a continuous ycovering of the base elements. These base pieces will then be secured tothe support' and cover pieces applied in the same manner described withrespect to the initial course of units.

l As heretofore indicated, the vertical joints between cover pieces areprotected by suitable weather-resistant batteri or joint pieces, whichare suitably set in recesses provided in the face of the base elements.Also, as 1previously indicated, where the cover pieces are detached itmakes little difference where these batten strips are positioned,l andin the instant Figure 8, the batteri piece H4 is shown as positioned aconsiderable distance from the end edge H6 of a base piece |04. Thecover pieces in this figure are shown -to completely protect the jointbetween base pieces and to break joints with the adjacent cover piecesimmediately abovethe battens H4. Obviously, as previously indicated, thehatten or joint pieces, in this instance H4, may be cemented or securedas by nails to the base piece either prior to or during application. Itwill be seen from Figure 8 that the upper and lower edges of the battenpieces H4 are substantially ush with the upper and lower edgesrespectively of the outer face of the base piece |04.

nIn the units of Figure 10, the base piece H8 is of somewhat differentshape .than that of Figure 9, the base H8 having an outward taperedface, as well as a tapered butt edge Iportion |20 which provides anoverhanging water drip. In this arrangement -the bases H8 Iare securedas by n-ails |22 near their butts to-.the supporting surface and thecover pieces |24 are slid into position, the cover .piece being providedwith a lower hook portion to t the portion |20 of the base H8. It willbe noted that the upper edge faceof the base is substantially parallelto that at its lower end and that the cover piece |24 has a formedportion |26, which nests against this upper face. As shown, fasteningmeans such as nails |28 are secured through the portion |26 of Ithecover piece and through-the base H8 at itsthin end to secure the coverpiece in position and to further aid in holding the base H8 against itssupporting surface. Subsequently, the next course of composite units arelaid with the hook portion of the cover piece bearing against thevportion |26 of the cover piece of the subjacent course. It will beunderstood that in positioning the base pieces H8 of the subsequentcourses, a temporary space piece should be preferably employed inmounting Ithe base lpieces to provide for the thickness of the hookportion of :the cover piece, or alternatively the base and -cover piecemay be mounted as a unit and the cover piece slid along to expose thenailing positions for the base. Obviously, joint or batten lpieces |30may be provided as described with respect to the previous figures. p

In Figures 11 and 12, a novel arrangement is provided adaptable forapplication over a clapboard siding and wherein it is desired toreproduce a clapboard effect with the composite units of my invention.The base pieces |32, in this modification, lhave substantially parallelfaces and substantially square lower edge faces. The upper edge por-tionof the bases |32 have outer notches forming lips or projections |34, thedepth of which is determined by the amount of lap vto be obtainedbetween adjacent vcourses of composite uni-ts. 'Ilhe cover pieces |36have a hooked lower portion which fits over the butt portion of the basepieces and the upper edge portions of the cover pieces are formed withVreverse L portions |38, which nest with the upper edge notches of thebase pieces |32. 'I'he thickness of the base lip portion |34 isdetermined by the amount of stepback of the original clapboard sidingandis made such that its thickness, plus the thickness of two asim endabutment and with their upper edges abutting the outwardly extendingbutt of the next higher clapboard and secured as by nails |40 at a lowerportion, in place. The,cover piece or pieces are then slid intoposition. Subsequently, the next lower or higher courses of base piecesare secured in -place and their cover pieces liketwise slid intoposition. It will be noted that the composite units here illustrated areof such depth that the butt of one unit projects below the clapboardagainst which it is secured, and laps the upper or thinned portion ofunits in the subjacent course, thereby holding the cover pieces of thesubjacent units in position .and avoiding any nailing or other fasteningthereof. Batten or joint strips |42 may be provided to protect thejoints between adjacent cover pieces and these may be of the characterand locatedas heretofore described with respect to previousarrangements. In the present construction, it will be noted, however,.that the hatten .piece |42 sets in a recess at the end of each basesection and, furthermore, the batten piece is so shaped as to follow therecess at the upper edge portion of the base pieces so as to extendweather protection to the la-p portion between courses.

In Figures 13 and 14, an arrangement is shown of insulating members withcover pieces, which may -be laid in courses wide spaced or butting, withadditional cover pieces providing weather protection between adjacentends of units in the same course. The addi-tional cover pieces m-ay beof .the same width or of random Width and their wid-th will determinethe amount of wide spacing between any two adjacent composite units. Inthis manner, many novel surface effects may be obtain-ed land it will beappreciated that batten or joint strips of the character described withrespect to the previous figures are made unnecessary according lto theconstruction here disclosed. Thus, eachcourse in the arrangement ofFigure 13 'comprises base pieces |44, base cover pieces |46 and jointcover pieces |48. The lower edge portion of the base piece |44 isnotched at its rear face to form a lip or piece |46 may be made apermanent part of thek base |44 but preferably is a loose piece.Obviously, by means of the two indicated hooks, it may be assembledwith-the bases before application and held thereto without additionalsecuring means. Even if the upper hook be omitted, the assembly may beconducted without presecurement of the cover piece l| 46 to the base|44. However, it is preferred, in such instance, that the cover piece betacked to the base by cement or other suitable means. This may be done.before or during application and merely assures the proper positioningof the joint cover piece |48. In assembly, the rear face of the Ibase|44 will be .positioned against the outer face of the cover piece |46 ofunits in the next lower course, -thereby overlapping said lower courseof units. Y

The depth of the joint cover piece |48 in said lower course will be madesuch that its upper which ts the lip |62 of the base |58.

extent of the overlap. In order that the rear face of the base |44 maybe .positioned as described, it is preferred` that the Adepth of therecess normal .to the rear face of the base be at least equal to thesummation ofthe thicknesses of the .base and joint cover piece underturned portions and the thickness of the joint cover piece in the nextlower course at its upper end where it underlies the said base |44. Byproviding the recessing described, a fastening means such as a nail |54may be secured through the base |44 immediately adjacent the upper edgeportion of the composite unit'which it overlaps. Next, the

y cover .piece |46 will be lpositioned and preferably tacked in place,as previously described. Thereafter, when the adjacent base and coverpiece have been secured in place, the joint cover member will -be hookedinto position over the base cover pieces and fastened as by nails |56 atthe upper edge of the units. These nails |56 will pass through a jointcover piece, the base cover piece and base, into the support. 'I'he baseand joint cover pieces wi-ll preferably be of similar material and maybe similarly or differently ornamented, as desired. Obviously, when thenext course of units are laid, the fasteners |56 will be lapped and.thereby protected. It will be noted that dead air spaces are providedin each course at the rear of each course of units, and in this manneradditional insulation protection is obtained. Moreover, it should beunderstood that the combination of double cover pieces and wide spacingeffect here disclosed in Figure 13 in connection with lbases |44, maysimilarly be carried out without the base element |44 and a continuousweather covering therebyv produced. In such cases, the pieces 46 mayhave their hook portion omitted or retroverted against the face of thismember Where desired.

In Figures 15 and 16, I have shown a further arrangement of compositeunits of my invention thickness of the upper e'dge portion of the base-|58 should not exceed the step-up between ladjacent clapboards and wherethe Vbases are made v tapered, the amount of` tapering should not besuch as to prevent proper placement of the cover pieces |60, as willhereinafter be understood.

'Ihe lower edge portions of the bases |58 are preferably recessed uponthe rear face to form a lip |62, the depth of the recess beingpreferably at least .the thickness of the cover piece ma.- terial. Itwill be observed from Figure |6 that the base |58 is made preferably ofa depth substantially that of the clapboard or wood shingle facing. Thecover pieces |60 are formed at their lower edge portion with aturned-under hook The face of .the cover piece is made of greater depththan the ybase |58 so that it may extend beneath the next overlying basein assembly and lbe secured in place. In assembly, the base pieces |58will be positioned and fastened. as by nails |64 near the lower .buttportion, said nails also, where desired, passing through the upper endof the cover piece |60 of the adjacent lower course of units.Thereafter, the cover pieces |60 will be hooked in place and their upperends fastened against the next higher clapboard or shingle facing as bynails |66. In `order to provide weather pro- -tection at the jointsbetween cover pieces in any course, I may employ joint pieces or batteristrips as 4have heretofore been described, and which will be the depthof the base pieces |58. However, in the present construction I prefer,in order to simplify assembly and avoid the handling of thin battenstrips, .to back up .the joint with a separate piece |68 of similarsection Ito the bas-e pieces |58 and of similar or other material whichhas `-been suitably treated as by coating or impregnation with awater-resistant compound, for instance, a bitumen or synthetic resin.The pieces i68 will be of sufficient width to provide a properweatherdap, and in assembly will be placed in position as any other basepiece |58 with its ends substantially abutting the adjacent end of thebase pieces |58. A joint piece |68 may be fastened as by nails to thesupport in the covered portion or may be left a loose piece to beslipped in when assembling the cover pieces From a consideration of theforegoing description of my invention, it will be seen that I haveproduced novel surface covering products and siding constructionsthereof. Also, I have shown many novel methods of assembly. I desire itto be understood that while certain figures of the drawings indicate theuse of joint or batten strips to protect the joints between adjacentcover pieces in a course, these may be omitted where the base has itselfbeen treated to be weatherresistant, at least in the portion surroundingthe joint between adjacent cover pieces. It will further be understood.that m-any changes in .the foregoing exemplified constructions willsuggest themselves to those skilled in the art without departing fromthe scope and spirit of my invention. Accordingly, I desire my inventionto be constructed as including all equivalents and as broadly as theclaims, when taken in conjunction with the prior art, may allow.

I claim:`

1. A surface .covering element comprising a pliable foundation layer,said layer having an edge por-tion bent to present an angular lip toengage the edge of a companion piece when assembled, and said layer and-lip having a hardened and non-softening coating rigidifying thebend'thereof whereby to resist relative displacement of said portions,the surface of said foundation layer Where said coating is applied beingof roughened character to anchor said coating.

2.*In a building structure, the combination comprising a stiff heat andcold insulating base and a weather cover piece therefor, comprising aweather-resistant non-metallic body portion and a preformed hook-likelip at an edge thereof engaging an edge of said base, said hook-like liphaving a hardened and non-softening coating rigidifying the bend of saidhook.

3. The vcombination comprising a heat and cold insulating base having apair of marginal lips at one edge and a weather-resistant cover piecefor said base, Ihaving a bent marginal portion interfitted with one ofsaid base lips, the second lip constituting an exposed fasteningprojection for the composite structure and said cover piece having itsopposite marginal portion extending over .the edge of said base oppositesaid lips whereby to lie between the lips of an adjacent similar base inassembly and overlie .the second lip of said base.

4. Thecombination comprising a heat and cold insulating base and aweather-resistant cover piece therefor, said base having a front and arear lip and a recess at its butt edge and said cover piece having abent marginal portion intertted with said front lip and having itsopposite edge portion projecting beyond the opposite edge of said basewhereby t-o interlock in the recess of an adjacent base in assembly,said rear lip projecting beyond said front lip to provide an exposednailing means for said base and being covered in assembly by theprojecting cover piece of an interlocking base.

5. A siding covering comprising a support and overlapping courses ofcomposite units each comprising a heat and cold insulating base and aweather-resistant cover pieceP therefor, said base having a projectinglip at its butt edge and said cover piece having a Ibent butt edgeportion, each base being secured to said support by fastening meansadjacent its butt edge and each cover piece having its bent portionabutting the said lip of a base in the same course and being secured byadditional fastening means adjacent its upper edge, said rst namedfastening means being covered by said cover piece and said second namedfastening means being covered by the overlapping lip of a composite unitin the adjacent overlapping course.

6. The combination comprising -a heat and cold insulating base and acover piece therefor, said base having a marginal depression at an edgethereof, and said cover piece having a bent Ipor'- tion intertting withsaid depression and -another bent portion intertting with .the oppositeedge of said base.

7. A weather siding comprising a clapboard surfacing and courses ofcomposite units as claimed in claim 6 secured thereto, the compositeunits in each course being secured in place with their upper base edgesabutting the butt edge face of a clapboard and with their depressedcover portions overlapped by the butt portion of composite units of anadjacent higher course of units.

8. A weather covering comprising a support and overlapping courses eachcomprising a plurality of combined members comprising bases and coverpieces therefor having bent butt portions, said Ibases being secured tosaid support and said cover .peices covering said bases and having theirbent butt por-tions engaged with the butt edges of said bases, and therebeing additional cover pieces in each course also having a bent buttportion, said latter cover 4pieces overlying the joint between theadjacent iirst named cover pieces of the same course and having theirbent butt portions engaged with the bent butt portions of said firstnamed underlying cover pieces in the same course.

9. A weather covering as claimed in claim 8, wherein the bases comprisestii heat and cold insulating members of greater thickness than thecover pieces.

10. A Weather covering as claimed in claim 8, wherein the rst namedcover pieces are wide spaced in the courses and wherein the joint coverdepth than the bases and having bent butt .portions, the bases in eachcourse arranged with their upper edge faces substantially abutting thebutt edge face of a clapboard and with the end edge faces of adjacentbases adjoining each other, and the cover pieces -havingvtheir bentportions engaged with the butt edges of the bases in the same course andoverlapping the next higher clapboard against which their bases'abut andsaid cover pieces underlying the bases of the next course of units; theadjacent courses of units overlapping each other and there beingweatherresistant material backing up :the joints between adjacent cover.pieces of the same course.

13. A siding structure as claimed in claim 12, wherein the jointsbetween adjacent cover pieces are backed up by weather-resistant insertsof similar vertical sections to .the bases and of sufcient width toprotectsaid joints against the weather.

14. A siding unit comprising a substantially stiff weather-resistantbase having a butt portion to lap an adjacent unit in assembly andproduce a clapboard lap eiect and having a flexible strip providing anexposed fastening extension .to be covered in assembly, projectingbeyond said lap portion whereby .to secure said unit to the support, apant of -said extension being spaced from said lap portion to form alocking groove to receive the underlying portion of the adjacent unit.

15. A siding assembly comprising a support and courses of units, ealchcomprising a substantially stiif base having a butt .portion to lap anadjacent unit and having a flexible strip providing a fasteningextension exposed during mounting, which projects beyond said lapportion and part of which is spaced from said lap portion to form allocking groove, each unit being secured to the support by nails driventhrough said fastening extension and said locking groove being engagedwith the end of an adjacent unit.

16. A roofing and siding element comprising a pliable foundation layerhaving a retroverted marginal portion forming an upwardly directed hookto interlock with an underlying member when assembled, and a hardenedand rigidifying coating comprising hydraulic cement extending over theportion of said element -to be eXpos'ed and around :the bend of saidretroverted portion whereby to rigidify said foundation layer to make itmore readily handled and whereby to rigidify said retroverted portion toresist relative displacement in assembly.

1'7. A weather siding comprising a support, longitudinal courses ofinsulating bases and cover pieces therefor secured to said support, saidbases being positioned substantially end to end and the cover piecesoverlying 4the top faces of and having bent portions engaged with thebutts of the bases in the same course. said cover pieces breaking jointbetween the opposite ends of an underlying base and there being a layerof weatherresistant material on said base and straddling said joints andsubstantially flush with the ytop faces of said bases, said layerextending transverselyl from -the butt edges of the bases to a positionunderlying the corresponding butt edges of similar bases in the adjacenthigher course.

18. A roofing and siding element as claimed in claim 16, wherein theleading edge of Ithe retroverted portion is tapered.

19. A roofing andsiding element comprising a i of the portions thereofin assembly.

NORMAN P. HARSHBERGER.

